Enclosure and method therefor

ABSTRACT

An enclosure includes a base. A frame includes a plurality of frame members. The frame members are coupled together and to the base using clips. Each clip includes a base coupled to a side surface of a first frame member. The clip further includes at least one lip extending from the base. The lip is sufficiently raised from the side surface of the first frame member to accept at least a portion of a second frame member between the lip and the side surface. A plurality of panels is coupled to the frame members. At least one panel is coupled to the base.

CLAIM OF PRIORITY AND RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Application No. 60/968,254, filed Aug. 27, 2007, entitledENCLOSURE AND METHOD THEREFOR, the contents of which are incorporated byreference herein.

TECHNICAL FIELD

This document pertains generally to enclosures, and more particularly,but not by way of limitation, to a double-walled enclosure for a rooftopheating, ventilating, and air conditioning (HVAC) system.

BACKGROUND

It is generally known to provide enclosure systems for rooftop HVACsystems. For instance, such systems typically are custom manufactured toaccommodate the HVAC system to be installed. Such enclosure systems haveseveral drawbacks. For instance, the known enclosure systems often havemoisture problems in that condensation tends to form within theenclosure. For instance, components, in particular, panels of knownenclosure systems often “sweat”. This occurrence is often caused, atleast in part, by metallic pathways, or through-metal, between aninterior surface and an exterior surface of the component of theenclosure system. For instance, a panel or other component of theenclosure system having continuous or abutting metallic portions exposedto both the interior and the exterior of the enclosure system can pose arisk for sweating within the enclosure system. Additionally, suchenclosure systems often require relatively extensive measuring, cutting,drilling, etc. of at least some of the components during assembly of theenclosure systems, which could result in an increased amount of timerequired for assembly, as well as increased costs.

What is needed is an enclosure system that overcomes the shortcomings ofprevious enclosure systems.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which are not necessarily drawn to scale, like numeralsdescribe substantially similar components throughout the several views.Like numerals having different letter suffixes represent differentinstances of substantially similar components. The drawings illustrategenerally, by way of example, but not by way of limitation, variousembodiments discussed in the present document.

FIG. 1 is a perspective view of an example of an enclosure in accordancewith an embodiment of the present invention;

FIG. 2 is a perspective view of the enclosure of FIG. 1 having panelsremoved to expose frame members;

FIG. 3 is a perspective view of an example of a base of the enclosure ofFIG. 1;

FIG. 3A is a side view of an example of an end of a cross member of thebase of FIG. 3;

FIG. 3B is an enlarged fragmentary view of a joint between base framemembers of the base of FIG. 3;

FIG. 4 is a cross-sectional view of an example of a frame member of thebase of FIG. 3;

FIG. 5 is a cross-sectional view of an example of a frame member of thebase of FIG. 3;

FIG. 6 is a perspective view of the frame members of FIG. 2 having thebase removed;

FIG. 7 is an exploded view of an example of a frame member of theenclosure of FIG. 1;

FIG. 8 is a perspective view of the frame member of FIG. 7;

FIG. 9A is a perspective view of examples of first and second framemembers of the enclosure of FIG. 1, the first and second frame membersshown disengaged from a clip;

FIG. 9B is a perspective view of an example of the clip of FIG. 9A;

FIG. 9C is an end view of an example of the clip of FIG. 9A;

FIG. 10 is a perspective view of the first and second frame members ofFIG. 9A; the first frame member engaged with the second frame member.

FIG. 11 is a perspective view of an example of a panel of the enclosureof FIG. 1;

FIG. 12A is a cross-sectional view of the panel of FIG. 11;

FIG. 12B is an enlarged fragmentary view of a portion of the panel ofFIG. 12A;

FIG. 13 is a perspective view of an example of a panel of the enclosureof FIG. 1;

FIG. 14 is a cross-sectional view of the panel of FIG. 13;

FIG. 15 is a perspective view of an example of a panel of the enclosureof FIG. 1;

FIG. 16 is a cross-sectional view of the panel of FIG. 15;

FIG. 17 is a perspective view of an example of an electrical panel ofthe enclosure of FIG. 1;

FIG. 18 is a cross-sectional view of the electrical panel of FIG. 17;

FIG. 19 is a cross-sectional view of the enclosure of FIG. 1;

FIG. 20 is an enlarged fragmentary view of a portion of FIG. 19, theportion denoted by the label “FIG. 20”;

FIG. 21 is an enlarged fragmentary view of a portion of FIG. 19, theportion denoted by the label “FIG. 21”;

FIG. 22 is an enlarged fragmentary view of a portion of FIG. 19, theportion denoted by the label “FIG. 22”;

FIG. 23 is a cross-sectional view of an example of a jig for use inconstructing a panel, the panel being shown prior to insertion ofinsulation therein; and

FIG. 24 is a cross-sectional view of the jig of FIG. 23, the panel beingshown after insertion of insulation therein.

DETAILED DESCRIPTION

The following detailed description includes references to theaccompanying drawings, which form a part of the detailed description.The drawings show, by way of illustration, specific embodiments in whichthe present subject matter may be practiced. These embodiments, whichare also referred to herein as “examples,” are described in enoughdetail to enable those skilled in the art to practice the presentsubject matter. The embodiments may be combined, other embodiments maybe utilized, or structural changes may be made without departing fromthe scope of the present subject matter. The following detaileddescription is, therefore, not to be taken in a limiting sense, and thescope of the present subject matter is defined by the appended claimsand their equivalents.

In this document, the terms “a” or “an” are used, as is common in patentdocuments, to include one or more than one. In this document, the term“or” is used to refer to a nonexclusive “or”, unless otherwiseindicated. Furthermore, all publications, patents, and patent documentsreferred to in this document are incorporated by reference herein intheir entirety, as though individually incorporated by reference. In theevent of inconsistent usages between this document and those documentsso incorporated by reference, the usage in the incorporated reference(s)should be considered supplementary to that of this document; forirreconcilable inconsistencies, the usage in this document controls.

Referring to FIGS. 1-24, there are shown examples of an enclosuresystem, indicated generally at 10, in accordance with the presentinvention. The enclosure system 10 can be used, for instance, to enclosea rooftop heating, ventilating, and air conditioning (HVAC) system,although this is not intended to be limiting, as such an enclosuresystem 10 can be used to enclose other systems or objects and inlocations other than rooftops.

Referring initially to FIGS. 1 and 2, the enclosure system 10 includes aframe 30 and a base 20. The base 20 can be anchored, for instance, to arooftop or other area of a building. The frame 30 is, in one example,attached to the base 20, as will be described in greater detail below.The frame 30 includes a plurality of frame members 32, at least some ofwhich are coupled together or are coupled to the base 20. The framemembers 32 can be coupled together or to the base 20 using clips 50 (seeFIG. 9A), as will be described in greater detail below. In one example,the frame 30 further includes a plurality of double-walled panels 40coupled to at least some of the frame members 32. It is alsocontemplated that at least some of the panels 40 are coupled to the base20. In one example, the panels 40 are coupled to the frame 30 or thebase 20 using self-tapping screws, although it is contemplated thatother fasteners or means of fastening, such as welding or gluing, forinstance, are used. It is noted that the enclosure system 10 shown inthe figures is but one example and that different configurations, sizes,and shapes are contemplated herein and are determined on a case-by-casebasis depending upon that which is to be housed, location of theenclosure system, and the like.

Referring now to FIGS. 3-5, in one example, the base 20 includes baseframe members 22 configured in a generally closed shape. In one example,the base 20 includes at least four base frame members 22 having miterends 22A configured in a generally rectangular shape. In other examples,the base 20 can include more or less than four frame members 22 and donot require miter ends 22A, depending upon the desired shape andconfiguration of the base 20. The base frame members 22, in one example,are attached by welding the base frame members 22 end-to-end to form agenerally rectangular shape. Optionally, in one example, at least one ofthe sides of the base 20 includes more than one base frame member 22joined together at a joint 23, as shown in phantom in FIGS. 3 and 3B.For instance, if the desired length of a side of the base 20 exceeds thelength of the given base frame members 22, two or more base framemembers 22 can be joined to form the side. In one example, the ends ofthe base frame members 22 forming the joint 23 include a tab-in-slotconfiguration, which is welded to fixedly attach the two base framemembers 22. In other examples, the base frame members 22 have ends ofdifferent mating configurations or are joined in ways other than bywelding. In other examples, the base frame members 22 are joined usingother fastening devices, such as, for instance, bolts.

At least some of the base frame members 22, in one example, each have anopen G-beam configuration. That is, each of the base frame members 22are generally shaped like the letter “G” when viewed in cross section,each with a portion 22C extending outwardly from a channel section 22D.In one example, the portion 22C creates a generally flat landing forsupporting at least one of a first floor layer 24 and one or more crossmembers 26. The one or more cross members 26, in one example, have aC-beam configuration, although this is not intended to be limiting, asother configurations of the one or more cross members 26 arecontemplated, such as, for instance, I-beam configurations, T-beamconfigurations, box beam configurations, solid beam configurations, andthe like.

The first floor layer 24, in one example, is a generally rectangularpiece of metal sized to fit within the base frame members 22, supportedby the portions 22C of the base frame members 22. The one or more crossmembers 26, in this example, are disposed between two opposing baseframe members 22 and attached thereto. For example, referringspecifically to FIG. 3A, each of the cross members 26 includes a tab 26Aat each end thereof, the tabs 26A fitting within corresponding slots 22Bin at least some of the base frame members 22, enabling the crossmembers 26 to be welded in place. Alternatively, or in addition thereto,the cross members 26 can be attached using fasteners such as bolts,screws, and the like or by using some other fastening means, such asadhesive, clamps, or the like. The one or more cross members 26 functionto, in one example, structurally strengthen the base 20, making the base20 more rigid. While the above examples include one or more crossmembers 26 (three cross members 26 are shown in FIG. 3), it is notedthat it is not required to include any cross members 26 in the base 20.As such, it is contemplated that no cross members are used, forinstance, in the event that the base 20 is of sufficient structuralrigidity or is capable of carrying interior loads without any crossmembers.

In one example, the base 20 further includes a second floor layer,generally similar to the first floor layer 24. The second floor layer isengaged with the base frame members 22, for instance directly attachedto one or more of the base frame members 22 or directly attached to oneor more of the cross members 26. In one example, the first and secondfloor layers include an insulation cavity therebetween. In anotherexample, insulation is disposed between the first floor layer 24 and thesecond floor layer. The insulation can be made up of any type ofinsulation material, such as insulating foam, blanket insulation, rigidinsulation boards, or a combination thereof. In one example, theinsulating foam is polyurethane foam. In some examples, the first floorlayer 24 or the second floor layer can include at least one drainageopening, slot, vent, or the like to allow any moisture build-up withinthe enclosure system 10 to drain from within the interior.

Referring to FIGS. 6-10, in one example, the frame members 32 of theframe 30 are disposed in a box-like configuration of a desired size andshape to accommodate the desired contents, such as an HVAC system. Inone example, the frame members 32 are disposed in vertical andhorizontal orientations. In other examples, the frame members 32 can bedisposed in other orientations, depending upon the application, such asdiagonally.

Referring to FIGS. 7 and 8, in one example, the frame members 32 areeach formed by two channels, such as two C-channels 32A, 32B, coupledtogether. While C-channels 32A, 32B are shown, it is contemplated thatother types of channels or members are used to form the frame members32, provided the channels or members are capable of performing asdescribed herein. In one example, first and second C-channels 32A, 32Binclude at least one engagement feature 34 to couple the first andsecond C-channels 32A, 32B. In another example, the at least oneengagement feature 34 is of a lance-lock configuration having a firstengagement portion 34A of the first C-channel 32A configured tointerlock with a second engagement portion 34B of the second C-channel32B. While the frame member 32 shown in FIGS. 7 and 8 includes sixengagement features 34 having three engagement features 34 on each sideof the frame member 32, it is contemplated that there be more or lessthan six engagement features 34 arranged in different locations alongthe first and second C-channels 32A, 32B. Additionally, while theengagement features 34 are shown having the lance-lock configuration,further examples can include a different type of engagement feature,such as, but not limited to a tab-in-slot configuration; a detentconfiguration other than the above-described lance-lock configuration; adeformable member configuration in which a deformable member is bentinto position to attach the first and second C-channels; and a fastenersuch as a bolt, screw, pin, or the like. In still other examples, theframe members 32 can be retained together using adhesive, foam, or thelike. Further examples include frame members 32 having one-piececonstruction, such as a box beam configuration, an I-beam configuration,or the like.

The frame members 32, in one example, include ends having inwardly bentlips or tabs 32C on two opposing sides. The other two opposing sides ofthe ends of the frame members 32 do not include such tabs, therebyforming an opening 32D on at least one of the sides. It is noted thatone of the sides of the end can be extended to close off one end of aslot formed by the tabs 32C, such that the frame member 32 then has onlyone opening 32D.

Referring now to FIGS. 9A, 9B, 9C, and 10, an example of engagement offirst and second frame members 32 using a clip 50 is shown. The firstand second frame members 32 are shown in a generally perpendicularorientation; however, it is contemplated that the first and second framemembers 32 are attached in a non-perpendicular orientation. The clip 50includes a mounting surface or base 52 having at least one fastener hole56 for affixing the clip 50 to a surface of the first frame member 32using a fastener such as a bolt, screw, or the like. One example of theclip 50 includes two fastener holes 56. Yet another example of the clip50 includes one fastener hole 56 and a protrusion extending downwardlyfrom the base 52 to engage within a corresponding hole or divot withinthe first frame member 32 to inhibit rotation of the clip 50 withrespect to the first frame member 32 or to hold frame members 32,coupled together using the clip 50, generally rigidly. Although thisexample includes a protrusion extending from the clip 50, a furtherexample contemplates a protrusion extending from the surface of thefirst frame member 32 to engage within a corresponding hole or divot inthe clip 50. Still another example contemplates a protrusion extendingfrom each of the clip 50 and the surface of the first frame member 32,the protrusions engaging within corresponding holes or divots in theclip 50 and the surface of the first frame member 32.

The clip 50, in one example, includes at least one formed edge or lip 54extending from the base 52. When the clip 50 is engaged with the firstframe member 32, the lip 54 is sufficiently raised from the side surfaceof the first frame member 32 to accept the tab 32C of the second framemember 32 between the lip 54 and the side surface. In another example,the clip 50 includes two lips 54, each of which are disposed on oppositesides of the clip 50. In yet another example, the opposite sides of theclip 50 are parallel. In still another example, the lips 54 are disposedon sides of the clip 50 that are tapered, such that the sides are closerto one another at one end of the clip 50 than at the other end of theclip 50 to form a wedge-like configuration to limit sliding motion ofthe second frame member 32 with respect to the clip 50. In one example,the clip 50 has a generally rectangular configuration with the oppositesides having a length greater than sides of the clip 50 disposed betweenthe opposite sides. The lips 54 in one example are formed edges that aregenerally parallel to and displaced from a plane X (see FIG. 9C) alignedwith the base 52. That is, the lips 54 extend generally within and alonga plane Y that is generally parallel and raised from the plane X alignedwith the base 52.

The clip 50 can accept one tab 32C of the second frame member 32 betweeneach lip 54 and the side surface of the first frame member 32, as shownin FIG. 10. In this way, the second frame member 32 can be slidablyengaged with the clip 50 attached to the first frame member 32. The clip50 is received through the at least one opening 32D in the end of thesecond frame member 32 to allow acceptance of the tabs 32C of the secondframe member 32 between the lips 54 of the clip 50 and the side surfaceof the first frame member 32 and, thereby, rigidly engage the end of thesecond frame member 32 with the lips 54 of the clip 50. While the abovedescribes engagement of two frame members 32, the description is equallyapplicable to engagement of a frame member 32 with a base frame member22.

Referring now to FIGS. 11-14, the double-walled panel 40 includes afirst shell 42 generally having a box configuration including aninterior region and a second shell 44 positioned with respect to thefirst shell 42. The second shell 44 is sized and shaped to correspondwith the box configuration of the first shell 42. In at least oneexample, the second shell 44 also has a box configuration including aninterior region. The first and second shells 42, 44 are configured tocooperatively nest. In one example, the first and second shells 42, 44include interior walls defining a cavity 45 within the panel 40. In oneexample, the first and second shells 42, 44 are formed metallic sheets.However, in other examples, it is contemplated that the first and secondshells 42, 44 are formed from non-metallic materials, such as, forinstance, plastic or some other polymeric material. In one example, thefirst and second shells 42, 44 are formed such that, when constructed,the panel 40 is hat-shaped. The term hat-shaped is used herein todescribe a shape of the panel 40, wherein the panel 40 has a first sideand a second side, similarly shaped to the first side, but smaller inarea and generally centered with respect to the first side, such thatthere exists a generally uniformly stepped arrangement around the sidesof the panel 40, as shown in FIG. 11.

The panel 40, in one example, includes a port 41 (FIG. 13) for insertingfoam 46, such as uncured liquid foam or other such materials, within thecavity 45 of the panel 40. The foam 46 of this example bonds to each ofthe first and second shells 42, 44, thereby coupling the first andsecond shells 42, 44. In one example, the foam 46 is encased within atleast the interior region of the first shell 42 and bonded to each ofthe first and second shells 42, 44, with the first shell 42 beingsubstantially held apart from the second shell 44. For example, the foam46 is interspersed between the first and second shells 42, 44 so thatthere is little or no direct contact between the first and second shells42, 44.

The first and second shells 42, 44 are separated by a predetermineddistance D. In one example, the first and second shells 42, 44 areinsulated from one another. For example, the foam 46 is a urethane foaminsulation that is disposed within the cavity 45 and acts to separatethe first and second shells 42, 44 at all points so that there is nocontinuous metallic pathway (e.g., no through-metal) between the outersurfaces of the first and second shells 42, 44. Referring to FIG. 12B,gaps A and B are formed between the first and second shells 42, 44 withthe insertion of the foam 46. Because there is no through-metal, theformation of condensation on the surface of the panel 40 interior to theenclosure system 10 is limited, if not eliminated. While the abovediscusses the use of urethane foam insulation, it is contemplated thatthere be another type of insulation used, either by itself or incombination with urethane foam insulation or other types of insulation.Other examples further contemplate the use of air as insulation.

Referring specifically to FIG. 14, a panel 40 is shown in a doorconfiguration. The panel 40 of this example is fitted with a hinge 48and a gasket 49 so that the panel 40 can be used as a door to theenclosure system 10. The hinge 48 enables the panel 40 to be pivotedwith respect to the rest of the enclosure system 10 to allow access tothe interior of the enclosure system 10 without at least partiallydisassembling the enclosure system 10. The gasket 49 aids in sealing thepanel 40 to the rest of the enclosure system 10 to limit moisture,contaminants, and the like from entering the enclosure system 10.

Referring now to FIGS. 15 and 16, in another example, a double-walledpanel 40′ is Z-shaped. The term Z-shaped is used herein to describe ashape of the panel 40′, wherein the panel 40′ has a first side and asecond side, each side being generally rectangular in plan view, thepanel 40′ having the sides offset such that the second side projectsbeyond the first side along at least one of the edges of the panel 40′and the first side projects beyond the second side along at most thethree remaining edges of the panel 40′, as shown in FIG. 15. In anotherexample, the first and second sides of the panel 40′ are offset suchthat the second side projects beyond the first side along two of theedges of the panel 40′ and the first side projects beyond the secondside along at the two remaining edges of the panel 40′. The Z-shapedpanel 40′ includes generally similar features and elements to thoseshown and described above with respect to the hat-shaped panel 40. Assuch, similar features and elements are labeled in the drawings withsimilar numbers as those shown with respect to the hat-shaped panel 40in FIGS. 11-13, differing only in that a “prime” symbol has been addedafter each number. For instance, a port 41′ of the Z-shaped panel 40′ isgenerally similar to the port 41 of the hat-shaped panel 40. Therefore,because, excluding the shapes thereof, the panels 40, 40′ are generallysimilar, further description of the features and elements of the panel40′ is omitted.

Referring to FIGS. 17 and 18, a compartment 60 for the enclosure system10 includes first and second walls 62, 64, which, in one example, areconfigured such that there is no through-metal in order to limitcondensation formation within the enclosure system 10. In one example,the compartment 60 includes a cavity 65 to receive a foam or other typeof insulation between the first and second walls 62, 64. In one example,the second wall 64 includes a flange 64A, through which fasteners aredisposed to attach the compartment 60 within the enclosure system 10 byattaching the compartment 60 to frame members 32.

The compartment 60, in one example, is used to house an electrical panel66. It is contemplated in other examples that the compartment 60 can beused to house or otherwise contain objects other than or in addition tothe electrical panel 66. In one example, the compartment 60 includes adoor 68 configured to close off the compartment 60 when closed and allowselective access to an interior of the compartment 60 when open. Forinstance, in one example, the door 68 is hinged to pivot about an axisbetween open and closed positions, with at least one hinge positionedbetween the door 68 and the first wall 62. Different examples of thedoor 68 can be configured to open inwardly or outwardly with respect tothe compartment 60 depending upon various factors such as spaceconstraints and location of the enclosure system 10, for instance. Inother examples, the door 68 moves in various manners to accomplish openand closed positions, such as, for instance, sliding, being removable,being foldable (a bi-fold door, for instance), or the like.

Referring to FIGS. 19-22, an example of the enclosure system 10 showsthe hat-shaped panels 40 attached to the frame members 32. In thisexample, vertically-oriented frame members 32 are attached to the baseframe members 22 (not shown in the figures) or horizontally-orientedframe members 32 using clips 50, as described above and shown in FIGS.9A and 10. The frame members 32 are spaced to accommodate the panels 40therebetween, such that the first shell 42 of each panel 40 forms aportion of the exterior of the enclosure system 10 and the second shell44 of each panel 40 forms a portion of the interior of the enclosuresystem 10. The panels 40 are positioned such that the stepped edges ofthe panels 40 partially encompass the respective frame members 32 towhich the panels 40 are mounted. In one example, the panels 40 areengaged to the frame members 32 using self-tapping screws, although itis contemplated that the panels 40 are engaged to the frame members 32in other manners, such as, for instance, bolts or other fasteners,adhesive, snap-in features, or the like. In one example, foam gaskets 33(see, for example, FIG. 22) or other such insulation members aredisposed between each frame member 32 and the respective panels 40 tolimit, if not eliminate, any through-metal pathways of the enclosuresystem 10. As shown in FIG. 20, the compartment 60, in one example, ismounted to the frame member 32 of the enclosure system 10. As shown inFIG. 21, a corner of the enclosure system 10 is formed using two framemembers 32 in this example, with one frame member 32 being used toattach the panels 40 and one frame member 32 acting as a filler to filla gap formed and thereby present a generally flush surface along eachside of the enclosure system 10. Referring to FIG. 22, at least onepanel 40 can form a door to the enclosure system 10, as described above,the hinge 48 of the panel 40 being mounted to the respective framemember 32 to allow pivoting of the panel 40 (the panel 40 on the left inFIG. 22) with respect to the rest of the enclosure system 10.

It is noted that the Z-shaped panels 41′ can be used to form theenclosure system. However, the Z-panel enclosure system differs from theenclosure system 10 described above at least in that, due to theZ-shaped configuration of the panels 40′, at least some of the interiorframe members 32 (e.g., the frame members 32 disposed between thecorners of the enclosure system) are eliminated. Depending on theconstruction and the strength or structural rigidity of the panels 40′,it is contemplated that the corner frame members 32 are eliminated inone example.

Referring now to FIGS. 11-13, 23, and 24, in another example, thepresent subject matter further includes a method of constructing thepanel 40. In this example, the first skin or shell 42 is placed, forinstance, on a first surface 102 of a jig 100 or other fixture suitablefor use in constructing the panel 40. The first shell 42 includes aninterior surface. The second skin or shell 44 is placed, for instance,between the first surface 102 and a second surface 104 of the jig 100 orother fixture suitable for use in constructing the panel 40. The secondshell 44 includes an interior surface. In one example, the first andsecond shells 42, 44 are positioned in a generally nestingconfiguration. For example, the first and second shells 42, 44 arecooperatively nested in a generally stacked configuration, with one ofthe first and second shells 42, 44 at least partially positioned withinthe other of the first and second shells 42, 44.

Uncured foam 46 is inserted within at least the interior region of thefirst shell 42. In one example, the introduction of the uncured foam 46causes the first shell 42 to separate from the second shell 44. Spatialpositioning of the first and second shells 42, 44 is maintained toinhibit separation of the first and second shells 42, 44 beyond aseparation distance, with the foam 46 curing and bonding to each of thefirst and second shells 42, 44. In one example, the jig 100 or otherfixture is provided to limit the separation distance of the first andsecond shells 42, 44 to the predetermined distance D.

In one example, the first and second shells 42, 44 are positioned in astacked configuration with the interior walls of the first and secondshells 42, 44 defining the cavity 45 or void therebetween. In oneexample, the foam 46 is inserted or otherwise introduced within thecavity 45 between the first and second shells 42, 44. The foam 46, inone example, bonds with the interior walls of the first and secondshells 42, 44 and, in this way, acts to maintain coupling of the firstand second shells 42, 44. In one example, the foam 46 is introducedthrough the port 41 in one of the first and second shells 42, 44. Inanother example, the foam 46 is placed onto the interior surface of oneof the first and second shells 42, 44 and then the other of the firstand second shells 42, 44 is positioned in the stacked configuration toconfine the foam 46 within the cavity 45. In another example, the foam46 is uncured when inserted within the cavity 45. In still anotherexample, the uncured foam is introduced in the cavity 45 by coupling anozzle to the port 41 or orifice disposed in at least one of the firstand second shells 42, 44. Once inserted, the foam 46 expands, thuscausing the first and second shells 42, 44 to separate. Separation ofthe first and second shells 42, 44 of this example is constrained by theseparation of the first and second surfaces 102, 104 of the jig 100,such that the first and second shells 42, 44 become separated by thepredetermined distance D. In this way, spatial positioning of the firstand second shells 42, 44 is maintained, and generally uniform widthpanels 40 can be produced. In one example, once the cavity 45 issufficiently filled with foam 46, the foam 46 is cured or otherwiseallowed to set. In one example, at least one of the first and secondsurfaces 102, 104 of the jig 100 is adjustable so that the separationdistance can be adjusted. Once positioned, however, the first and secondsurfaces 102, 104 are substantially rigid. Once the foam 46 cures, thepanel 40 is removed from the jig 100. Removal of the panel 40, in oneexample, is accomplished by sliding the panel 40 out from between thefirst and second surfaces 102, 104. In another example, removal of thepanel 40 is accomplished by adjusting one of the first and secondsurfaces 102, 104 to increase the separation therebetween and thensliding the panel 40 out from between the rigid first and secondsurfaces 102, 104. It is noted that, although not shown, this method ofconstruction is equally applicable in constructing the Z-shaped panel40′, as shown in FIGS. 15 and 16.

Referring generally to FIGS. 1-10, in yet another example, the presentinvention further includes a method of manufacturing the enclosuresystem 10. A plurality of frame members 32 are received, the framemembers 32 including at least first and second frame members 32. Atleast the first frame member 32 has a hole pattern to receive at leastone mounting clip 50 (see FIGS. 9A and 10). The hole pattern, in oneexample, corresponds to a single configuration of clip locations. The atleast one clip 50 is attached to the first frame member 32. As discussedabove, the clip 50 has a mounting surface 52 for attaching to the firstframe member 32 and a pair of formed edges or lips 54 disposed onopposite sides and displaced from a plane aligned with the mountingsurface 52. The second frame member 32 is then coupled to the at leastone clip 50 by engaging an end of the second frame member 32 with thepair of lips 54. In one example, the end of the second frame member 32is engaged to the first frame member 32 by sliding the second framemember 32 in a direction parallel with a longitudinal axis of the firstframe member 32. At least one double-walled panel 40 is then attached toat least one of the first and second frame members 32. In one example,at least some of the frame members 32 have alignment marks thereon thatindicate to an assembler the correct configuration of joints and, thus,the correct configuration of the assembled enclosure system 10.

Referring now to FIGS. 1-3, the method, in one example, further includesconstructing the base 20 by receiving at least four base frame members22 having miter ends 22A. The base frame members 22 are coupled togetherto form a generally rectangular shape. Optionally, as discussed above,in one example, at least one of the sides of the base 20 includes morethan one base frame member 22 welded or otherwise joined together at ajoint 23, as shown in phantom in FIGS. 3 and 3B. At least the firstfloor layer 24 is positioned on the base frame members 22. In oneexample, at least one cross member 26 is positioned between two opposingbase frame members 22. The at least one cross member 26 of one examplehas a tab 26A extending from an end of the cross member 26, so that thetab 26A can be disposed within a corresponding slot 22B in the baseframe member 22. In another example, constructing the base 20 furtherincludes engaging a second floor layer with the base frame members 22.

It should be understood that other methods of manufacture orconstruction of the enclosure system 10 or the double-walled panel 40,40′ are within the spirit and scope of the present invention. Forinstance, it is contemplated that use of the Z-shaped panels 40′ toconstruct an enclosure system can eliminate at least some of the framemembers 32. That is, the panels 40′, due to their shape, allow fordirect panel-to-panel connections in at least some circumstances,thereby limiting, if not eliminating, at least some of the frame members32.

In one example, the double-walled construction of the panels 40, 40′ andthe reduction of through-metal pathways curtail formation ofcondensation or “sweating.” Also, the components allow for relativelyeasy, kit-like construction of the enclosure system 10, thereby reducingthe need for measuring, cutting, drilling, etc. of at least some of thecomponents during assembly of the enclosure system 10. By limiting oreliminating such extra steps, the amount of time required for assemblyof the enclosure system 10 is decreased.

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (or aspects thereof) may be used in combination with eachother. Many other embodiments will be apparent to those of skill in theart upon reviewing the above description. The scope of the subjectmatter should, therefore, be determined with reference to the appendedclaims, along with the full scope of equivalents to which such claimsare entitled. In the appended claims, the terms “including” and “inwhich” are used as the plain-English equivalents of the respective terms“comprising” and “wherein.” Also, in the following claims, the terms“including” and “comprising” are open-ended, that is, a system, device,article, or process that includes elements in addition to those listedafter such a term in a claim are still deemed to fall within the scopeof that claim. Moreover, in the following claims, the terms “first,”“second,” and “third,” etc. are used merely as labels, and are notintended to impose numerical requirements on their objects.

The Abstract of the Disclosure is provided to comply with 37 C.F.R.§1.72(b), requiring an abstract that will allow the reader to quicklyascertain the nature of the technical disclosure. It is submitted withthe understanding that it will not be used to interpret or limit thescope or meaning of the claims. In addition, in the foregoing DetailedDescription, various features may be grouped together to streamline thedisclosure. This method of disclosure is not to be interpreted asreflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive subject matter may lie in less thanall features of a single disclosed embodiment. Thus the following claimsare hereby incorporated into the Detailed Description, with each claimstanding on its own as a separate embodiment.

1. An enclosure, comprising: a base; a frame including a plurality offrame members, the frame members coupled together and to the base usingclips, each clip including a base coupled to a side surface of a firstframe member, the clip further including at least one lip extending fromthe base, the lip being sufficiently raised from the side surface of thefirst frame member to accept at least a portion of a second frame memberbetween the lip and the side surface; and a plurality of panels coupledto the frame members, at least one panel coupled to the base.
 2. Theenclosure of claim 1, wherein the base comprises: base frame membersconfigured in a generally closed shape; and at least a first floor layerdisposed on the base frame members.
 3. The enclosure of claim 2, whereinthe base comprises at least one cross member disposed between two baseframe members.
 4. The enclosure of claim 2, wherein the base comprises asecond floor layer engaged with the base frame members.
 5. The enclosureof claim 4, wherein the base comprises an insulation cavity between thefirst and second floor layers.
 6. The enclosure of claim 1, wherein eachof the frame members includes two channels coupled together.
 7. Theenclosure of claim 6, wherein the channels of each of the frame membersare coupled together using at least one engagement feature.
 8. A method,comprising: attaching at least one clip to a first frame member, theclip having a mounting surface for attaching to the first frame memberand a pair of formed edges disposed on opposite sides of the clip, theformed edges being generally parallel to and displaced from a planealigned with the mounting surface; and coupling a second frame member tothe at least one clip by engaging an end of the second frame member withthe pair of formed edges.
 9. The method of claim 8, wherein engaging theend of the second frame member includes sliding the second frame memberin a direction parallel with a longitudinal axis of the first framemember.
 10. The method of claim 8, comprising constructing a base,including: coupling base frame members together to form a generallyclosed shape; and positioning at least a first floor layer on the baseframe members.
 11. The method of claim 10, wherein constructing the baseincludes attaching at least one cross member between two base framemembers.
 12. The method of claim 10, wherein constructing the baseincludes engaging a second floor layer with the base frame members. 13.The method of claim 8, comprising attaching at least one panel to atleast one of the first and second frame members.
 14. An apparatus,comprising: a first shell having a box configuration including aninterior region; a second shell sized and shaped to correspond with thebox configuration of the first shell, the first and second shellsconfigured to cooperatively nest; and foam encased within at least theinterior region of the first shell and bonded to each of the first andsecond shells, wherein the first shell is substantially held apart fromthe second shell.
 15. The apparatus of claim 14, wherein the secondshell has a box configuration including an interior region.
 16. Thepanel of claim 14, wherein the foam includes urethane foam insulation.17. The panel of claim 14, wherein the first shell is insulated from thesecond shell.
 18. The panel of claim 14, wherein the panel ishat-shaped.
 19. The panel of claim 14, wherein the panel is Z-shaped.20. The panel of claim 14, wherein the first and second shells areformed metallic sheets.
 21. A method, comprising: positioning first andsecond shells in a generally nesting configuration, at least the firstshell having a box configuration including an interior region, thesecond shell sized and shaped to correspond with the box configurationof the first shell; inserting uncured foam within at least the interiorregion of the first shell, the introduction of the uncured foam causingthe first shell to separate from the second shell; and maintainingspatial positioning of the first and second shells to inhibit separationof the first and second shells beyond a predetermined separationdistance, the foam curing and bonding to each of the first and secondshells.
 22. The method of claim 21, wherein the foam is inserted througha port within at least one of the first and second shells.
 23. Themethod of claim 21, wherein maintaining the spatial position of thefirst and second shells includes using a jig.
 24. A frame portion,comprising: a first frame member having a side surface; a second framemember having an end with at least one tab; and a clip including a baseconfigured for engagement with the side surface of the first framemember, the clip further including at least one lip extending from thebase, the lip being sufficiently raised from the side surface of thefirst frame member to accept the tab of the second frame member betweenthe lip and the side surface.
 25. The frame portion of claim 24, whereinthe clip has two lips, each of which are disposed on opposite sides ofthe clip.
 26. The frame portion of claim 25, wherein the second framemember includes two tabs, each tab configured to fit between thecorresponding lip of the base and the side surface of the first framemember.
 27. The frame portion of claim 24, wherein the at least one tabof the second frame member is selectively slidably engaged with the atleast one lip of the clip.
 28. A clip for assembling a first linearmember and a second linear member in perpendicular orientation, the clipcomprising: a mounting surface for attaching to the first linear member;and a pair of formed edges disposed on opposite sides of the clip, theformed edges being generally parallel to and displaced from a planealigned with the mounting surface, wherein the pair of formed edges areconfigured to receive an end of the second linear member.
 29. The clipof claim 28, further including at least one fastener hole disposed inthe mounting surface.
 30. The clip of claim 28, wherein the oppositesides are parallel to each other.
 31. The clip of claim 28, wherein theclip has a generally rectangular configuration with the opposite sideshaving a length greater than sides of the clip disposed between theopposite sides.
 32. The clip of claim 28, wherein the pair of formededges are configured to rigidly engage the end of the second linearmember.
 33. A method of manufacturing a wall structure, the methodcomprising: positioning a first skin and a second skin in a stackedconfiguration; providing a fixture to limit a separation distance of thefirst skin and second skin; introducing uncured foam in a void betweenthe first skin and the second skin; allowing the first skin and secondskin to separate to the separation distance; and curing the foam. 34.The method of claim 33, wherein introducing uncured foam in the voidincludes coupling a nozzle to an orifice disposed in at least one of thefirst skin and the second skin.
 35. The method of claim 33, whereinproviding the fixture includes positioning a rigid surface.
 36. Themethod of claim 35, further including displacing the rigid surface andremoving the first skin, second skin and the cured foam.